Continuous methods for producing mailable materials



May 6, 1969 E. J. BUESCHER 3,442,185

CONTINUOUS METHODS FOR PRODUCING MAILABLE MATERIALS Filed June 26, 1967Sheet; of 2 FIG.[

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CONTINUOUS METHODS FOR PRODUCING MAILABLE MATERIALS Filed Jun 26, 1967Sheet 3 of2 IIJ: 7L L .1 74 3 w v lli" g :2 i M i l l L FIGJO 72 74 FIGll FIG. [2

United States Patent 3,442,185 CONTINUOUS METHODS FOR PRODUCING MAILABLEMATERIALS Eugene J. Buescher, 2229 Entity Ave., St. Louis, Mo. 63114Filed June '26, 1967, Ser. No. 648,894 Int. Cl. B31b 1/88, 1/14, 1/36US. CI. 93-61 8 Claims ABSTRACT OF THE DISCLOSURE This invention relatesto a continuous method for preparing multiple items suitable formailing. More particularly, it relates to a method for preparing andaddressing these items from a multiple layer form suitable for use indata processing equipment.

Several methods have heretofore been proposed for utilizing the speed ofdata processing equipment for the preparation of items suitable formailing such as envelopes. These methods, in general, are an improvementover the older methods of addressing envelopes such as by placing gummedlabels, stenciling, address plates and the like because such continuousmethods utilizing data processing equipment yield a product having anappearance of a personally typewritten envelope. The methods utilizingforms suitable for data processing machinery heretofore known, however,are not completely free of handicaps. For example, one general methodutilizes a carrier strip upon which an envelope is attached until it isprocessed through the data processing equipment and the envelope isthereafter detached from the carrier strip. This method yields a largeamount of waste paper and the envelope when detached has a rough edgewhich detracts from the appearance of the product.

The present method enables the production of multiple mailable items byutilizing a unique method which overcomes many of the disadvantages ofprior processes. Furthermore, it has the flexibility to enable a largenumber of different types of mailable items to be produced. Such amethod is believed to be an advancement in the art.

In accordance with one aspect of this invention a multiple layer form,capable of being processed on data processing equipment, is printed onone of the external layers. This method requires that the paper be ofreproducible nature, that is a portion of the printing made on one layerwill be reproduced on subsequent layers. In accordance with anotheraspect of this invention a single layer form can be used for producingcartons. A heavy material that is heavier than a standard 24 lb. weightpaper is used to produce an addressed mailable carton. Heretobeforethese mailable materials were generally addressed by applying gummedlabels to the carton. In most instances, any standard paper having aWeight of greater than about 20 lbs., such as 125 lb. Weight issatisfactory although in some instances heavier paper can be used ifdesired. One of the preferred methods which will be described in detailhereinafter utilizes carbon paper between ice the layers forreproduction of the desired printing on the subsequent layers. Afterprinting, the form is separated into individual layers by any suitablemeans which step is known in the art as decollation. The carbon paper,if used, is separated from the layers at this step. The layers afterseparation are then bursted into easily divisible separate rectangularportions. The material which is used in the present commerciallyavailable data processing equipment will, generally, vary from about 13"to about 18". The layers before they are broken into individual portionsare generally several hundredfeet in length since normally a continuousmethod is used. The layers are easily divisible into rectangularportions having the foregoing widths and the depth of the portion can bevaried according to the product that is desired. For example, onestandard envelope in an unformed state would require a width of about 14to 15" and a depth of about 8 /2 to 9". Another standard envelope willrequire a depth of about 11 inches. Other mailable materials such ascartons, bags and the like will require different dimensions. Theparticular.size of the individual sheet will be variable and the sizewill generally be selected to minimize the amount of waste. Theprocesses of separating the material into the smaller portions is knownas bursting and wvill be used hereinafter as signifying the aboveprocess of separating the individual layers into the foregoing equalsize portions. Bursting is required after the separation step to enablestacking in a manner suitable for diecutting. In most conventionalprocesses utilizing data processing equipment the data containingmaterial is stacked in a convenient size by folding along the portionswhere the material is separated in the present method. It is essentialto the present method that the bursting step follow he decollation stepand that the sheets be in substantially complete alignment for reasonshereinafter explained.

Afer the layers are bursted into the individual sheets, the individualsheets are positioned in substantially complete alignment. That iscontiguous sheets are placed in a substantial identical position inrespect to each other. For example, messages on contiguous sheets are inthe same position, face the same direction and are readable from thesame position. By substantially complete alignment it is meant that theside containing printing is designated as the base and the opposing sideis designated as the back, the back of each individual sheet will beplaced upon or adjacent to the face of the succeeding sheet and the topof the printing on each sheet will be in same direction.

After the individual sheets are in alignment, the desired unformedmaterial is cut, normally diecutting will be used; however, knives, orslicers can be used in some instances. No special sorting is necessary.After cutting, the separate mailable items are formed to their desiredshape and are suitable for mailing or insertion into one of the mailableitems.

Each item contains printing which closely resembles typewriting. Ifbursting and alignment are not carried out prior to diecutting, theprinting will not be in the same relative location, thus causing eithera large amount of waste or requiring a completely symmetrical shape tothe uniform item.

As can be appreciated, the method of this invention has a large degreeof flexibility. For example, the outer layer can be cut to form anenvelope which has the appearance of an individually typed or windowenvelope. The subsequent layer can contain a preprinted message which isautomatically addressed during this method. A third subsequent layer canbe diecut to form a return envelope. The person receiving the originalenvelope is thereby relieved of writing his return address thus savinghim time and inconvenience.

These and other novel features of the present invention will be furtherexplained and set forth in reference to the drawings which form a partof this specification.

In reference to the drawings:

FIGURE 1 is a perspective view illustrating multilayer data processingforms which have been pro-printed and have been processed through thedata processing equipment. The forms are one of the preferredembodiments and have carbon paper between the layers which has beenprinted in accordance with a previous step.

FIGURE 2 is a perspective view illustrating the decollation step. Theform is separated into two individual stacks and the carbon paper isseparated at this step.

FIGURE 3 is a perspective view illustrating bursting step. Theindividual stacks are broken into individual rectangular sheets whichare stacked individually at this step.

FIGURE 4 is a perspective view illustrating a typical individual sheetfrom one layer of the form of FIGURE 1 and the portion of therectangular sheet which is to be diecut to form an envelope, one of thepreferred embodiments of this invention.

FIGURE 5 is a perspective view illustrating a typical individual sheetfrom the other layer of the form of FIGURE 1 and the portion of thisrectangular sheet which is to be diecut to form a return envelope.

FIGURE 6 is a perspective view illustrating the completed envelope ofFIGURE 4.

FIGURE 7 is a perspective view illustrating the completed envelope ofFIGURE 5.

FIGURE 8 is a perspective view illustrating the portion of one of therectangular sheets which is to be diecut to form another preferredembodiment of this invention.

FIGURE 9 is a perspective view illustrating the preferred embodiment ofFIGURE 8 in a semi-formed stage.

FIGURE 10 is a perspective view illustrating the preferred embodiment ofFIGURE 9 in a competely formed stage to form an envelope.

FIGURE 11 is a perspective view illustrating the formed envelope ofFIGURE 10 perforated along a particular line.

FIGURE 12 is a perspective view illustrating the envelope of FIGURE 11after opening along the perforation.

With specific reference to the drawings and with specific reference toFIGURE 1 a continuous multilayer form is pre-printed prior to use in thedata processing equipment with a message on the upper layer 22 hereillustrated as a return address 24. As the multilayer paper passesthrough a data processing equipment, the address 26 is printed upon theupper layer 22. The carbon paper 28 which is between the upper layer 22and the lower layer 30 causes the same message to be imprinted on thelower layer 30. After the printing is completed, the multilayer materialis folded into a stack 32 as illustrated in FIGURE 1.

With reference to FIGURE 2 in the decollation step, the upper layer 22,the lower layer 30 and the carbon paper 28 are each separated. The upperlayer 22 is folded separately to form a stack 40. The lower layer 30 isfolded separately to form stack 42.

With reference to FIGURE 3, the stack is bursted into individualrectangular portion 44 and placed in a stack 46 with each portion havingthe printing in the same relative location. In a similar manner, stack42 is separated into individual pieces and stacked.

With reference to FIGURE 4, a typical separated portion havingdimensions of about 9" X 14" 44 of the upper layer 22 is shown. A diecutis made throughout the portions of stack 46 along the lines shown toform an unformed envelope 48. The pre-printed message 24 and the dataprocessing printed message 26 appear on the unformed envelope.

With reference to FIGURE 5, a typical separated portion 50 of the lowerlayer 30 is shown. These portions are diecut to form an unformedenvelope 52. The address 54 which was reproduced on the lower layer 30is in a proper location for a return address. The mailing address 56which was pre-printed on the lower layer in the same manner as thereturn address 24 on the envelope 48 produced from the upper layer 22 isalso in the proper location.

With reference to FIGURE 6 the envelope 48 produced from the upper layer22 is shown formed and glued. The pre-printed return address 24 and theprinted address 26 are in a proper location for mailing.

With reference to FIGURE 7, the envelope 52 produced from the lowerlayer 30 is shown formed and glued. The printed return address 54 is inthe proper location for return mailing, and can be inserted into theenvelope 48 illustrated in FIGURE 6.

With respect to FIGURE 8, a rectangular portion 60 previously printed,and separated as described in reference to FIGURES 1, 2 and 3 is cut toprovide the unformed envelope 62. During the data processing step amessage such as a letter, an account statement and the like are printedon an extended portion 64 which extends from the body of envelope 66. Asmaller opposing extended portion 67 is formed.

With reference to FIGURE 9, which shows the combination envelope andmessage in a semi-formed position. The printed extended portion 64 isfolded and does not reach to the smaller opposing extended portion 67when it is folded along line 68.

With reference to FIGURE 10, a space 64 between the portions 69 is leftand the adjacent extended portions 70 and 72 are folded to form acompleted envelope 74.

With reference to FIGURE 11, the completed envelope 74 is perforatedalong a line which is from about A1." to about from the edge, connectingthe inner portion 64 to the body of the envelope 66. The address 82 isprinted in the data processing equipment at the same time the messagecontained on the inner portion '64 is printed. This method has theadvantage of insuring that the proper statement, message or letter issent to the person to whom the letter is addressed, thereby overcomingone of the inherent difiiculties with handling large volumes of accountsby normal hand-stuffing of envelopes.

With reference to FIGURE 12, the message 64 is easily removed from theenvelope 74 by placing one hand on the envelope at one side and theother hand on the other side 92 and imparting a slight separationmovement. The envelope separates along line 80 and the inner portion 64is attached to the detached part of the outer portion of the envelope94.

As can be appreciated, the method of this invention has a high degree offlexibility, both in the type of forms used and in the product produced.For example, the multi-layer forms can be paper, thin plastic sheets andfabrics, if desired. In most instances, paper will be used because ofits relative inexpensiveness and readily availability. Additionally, inmost instances, carbon paper will be inserted between the layers inorder to easily obtain reproduction on only selected portions of thesubsequent layer, although in some instances a pressure sensitivereproducing paper will be used, particularly if selected reproduction isnot needed. It is to be noted that from two to about four layers can beused when reproduction is desired. The particular number of layers willdepend upon the particular product that is to be produced. For example,when envelopes plus insertions into the envelopes are produced, 3 to 4layers can be utilized. When cartons are produced, generally a higherstrength material is required, therefore, in most instances, a one layercontinuous form can be used or a thin layer in combination with aheavier layer can be used. It is to be additionally noted that thelayers can be separately printed with the same or different printingprior to assembly into a continuous form. In the preparation of a cartonthe thin layer can be imprinted with the address and other pertinentinformation for a record of the mailing of the carton.

In the printing step a large degree of flexibility can also be achieved.For example, the address can be printed and will serve as the mailingaddress on the product originally mailed and as a return address or aninside address on the products produced from the other layers. As anillustration, it is desirable in many instances to send a form letterand a return envelope, In most instances, it is believed if the lettercontains the name and address of the individual to whom it is sent, abetter impression is created. If desired, coded information can be usedand suitable messages for optical scanning can be included, if desired.In this instance, a three-layer form can be used, one layer of themulti-layer form can be preprinted with the form letter and assembledwith two other layers, one of which the address to whom the returnenvelope is to be sent and the other containing the return address ofthe originally mailed envelope. As the form passes through the dataprocessing equipment, the name and adress of the person to whom thematerial is to be sent is imprinted on all three layers. In thesubsequent diecutting step the two envelopes are produced and theaddressed form letter. It is to be noted that in many instances ifdesired, additional printing can be done on selected pieces at thedecollation step or at the bursting step. It is to be noted that themultiple printing is not limited to addresses. For example, a billingstatement can be printed on each of two layers, one to be mailed and theother to become a file copy. Additionally where several mailings are tobe done to the same persons within a relatively short period of time,all of the layers can be converted into original mailed materials. Otheruses and types of printing can be readily appreciated by those skilledin the art.

It is to be emphasized that although the method of this invention hasbeen described in the drawings in reference to envelopes that this isnot considered a limitation upon the product that can be produced. Forexample, as previously mentioned, relatively light weight cartons can beproduced from one layer and enclosures to be placed inside these cartonscan be produced from the subsequent layers. Similarly, bags suitable formailing with enclosures can also be produced.

One of the aspects of this invention as described in reference toFIGURES 8, 9, 10, 11 and 12 constitute a novel product, that is, anenvelope which contains a message which an integral portion of theenvelope can be detached by the receiver. The length of portioncontaining the message and the length of the opposing portion are lessthan the width of the envelope. If the total length of these twoportions are greater than the width of the formed envelope, the portioncontaining the message would not be removed but would normally remain attached since the smaller opposing portion would be sealed to the body ofthe envelope. As previously mentioned,

this product insures that personal information will be mailed to thecorrect person as it will be printed simultaneously with the address.Errors in mailing the information to the wrong person would thereby bereduced. The envelope can be perforated at a distance from about A toabout from the edge to enable a sufiicient area for one to easily graspthe edge with the finger and thumb of one hand. The perforation step canbe done at any step subsepuent to diecutting and prior to forming.

What is claimed is:

1. A method for producing mailalble materials comprising (a) printing aplurality of messages on one layer of a reproducing continuous dataprocessing form having a plurality of layers, said form being separableinto continuous individual layers and each continuous layer beingdivisible into smaller individual sheets, (b) separating said layers,(c) dividing said layer into individual sheets, each individual sheetfrom said layer containing said messages also containing a message, (d)positioning said individual sheets in substantially complete alignmentwherein each contiguous sheet is in substantial identical position withrespect to each other, (e) cutting said sheets to produce an unformedmaterial and (f) forming said unformed material into a mailablecontainer.

2. A method according to claim 1, wherein said message is an address andwherein one layer is formed into a carton.

3. A method according to claim 1, 'wherein said message is an addressand wherein one layer is formed into an envelope.

4. A method according to claim 3, wherein two layers are formed intoenvelopes and wherein one address on one envelope is a mailing addressand on the other envelope is a return address.

5. A method according to claim 3, wherein one layer is formed into anenvelope and another layer contains a message for insertion into saidenvelope.

6. A method according to claim 1, wherein said layers are pressuresensitive reproducing paper.

7. A method according to claim 1, wherein one of the layer isconstructed of carbon paper which is positioned between two of saidlayers, and the additional step of removing said carbon paper from theprocess prior to dividing the layers into individual sheets.

8. A method according to claim 1, wherein said form is paper.

References Cited UNITED STATES PATENTS 3,104,799 9/1963 Steidinger28211.5 3,272,095 9/1966 Heuff 93--61 BERNARD STICKNEY, PrimaryExaminer.

U.S. Cl. X.R. 229; 282--l1.5

